Methods and Apparatus for Installing Sleeve on Cable Using Active Dimensional Analysis

ABSTRACT

An apparatus that melts and monitors sleeves for installation onto shielded cables. The apparatus includes a heat source for melting the sleeve, cable supports for supporting the cable during the melting process, a sensor system that is configured to measure a dimension of the sleeve during melting, and a computer that is connected to receive sensor data from the sensor system and send heater control signals to the heat source. The computer is configured to receive dimensional data from the sensor system, monitor that dimensional data by performing a dimensional analysis, and then deactivate or remove the heat source in response to dimensional analysis results indicating that the sleeve is fully melted (in the case of a solder sleeve) or only fully shrunken (in the case of a dead end sleeve) onto the cable.

BACKGROUND

This disclosure generally relates to methods and apparatus for processing cable. In particular, this disclosure relates to methods and apparatus for installing a sleeve on a cable.

Shielded cables incorporate shielding in an attempt to prevent electromagnetic interference. For example, the conductors may be surrounded by braided shielding made of metal. Because the shielding is made of metal, it may also serve as a path to ground. Usually a shielded cable incorporates a grounding wire that contacts the shield in an unjacketed portion of the shielded cable. Typically the grounding wire is attached using a solder sleeve comprising a tube made of thermoplastic material and a central solder ring. The solder sleeve is placed around exposed shielding on the end of a shielded cable and then the solder sleeve is heated, causing the thermoplastic material to shrink and the central solder ring to melt in place.

As used herein, the term “sleeve” means a tube made of shrinkable material, such as a solder sleeve made of thermoplastic material (which shrinks) and a solder ring (which melts) or a dead end sleeve made of thermoplastic material and having no solder ring. Installation of a solder sleeve involves shrinking of the thermoplastic material and melting of the solder ring; installation of a dead end sleeve involves shrinking of the thermoplastic material. As used herein, “melting a solder sleeve” includes shrinking the thermoplastic material with melting of a solder ring, while “shrinking a sleeve” includes shrinking the thermoplastic material with (e.g., solder sleeve) or without (e.g., dead end sleeve) melting of a solder ring.

Solder sleeve installation is a process that is currently performed manually by an operator. There are a range of tools that an operator may use to perform the melt of the solder sleeve; these tools typically use either hot air or infrared heat to activate the solder and shrink the sleeve. These tools are usually handheld, and all of them require the operator to visually monitor the melt progression of the solder sleeve.

A solder sleeve is considered fully melted based on physical appearance. However, there is a wide range of melt times associated with various solder sleeves and wire type combinations. Due to the variability of materials in solder sleeves and their large design tolerances, there is not a consistent timeline for melting to occur. Solder sleeves are limited in how quickly they are able to fully melt without burning, simply due to their design and materials. This high level of variability makes standardization of melt times and melt temperatures difficult to impossible. Because of this, operators are required to actively monitor solder sleeves as they are melted. This prevents operators from working on other tasks. There is a need for a consistent method of determining when a shrinking sleeve (with or without melting of a solder ring) has been sufficiently heated, regardless of material and temperature variations.

SUMMARY

The subject matter disclosed in some detail below is directed to a hands-free apparatus that melts and monitors solder sleeves and dead end sleeves for installation onto shielded cables. The apparatus includes a heat source for melting the sleeve, cable supports for supporting the cable during the melting process, a sensor system that is configured to measure a dimension of the sleeve during melting, and a computer that is connected to receive sensor data from the sensor system and send control signals to the heat source. The computer is configured to receive dimensional data from the sensor system, monitor that dimensional data by performing a dimensional analysis, and then deactivate the heat source in response to dimensional analysis results indicating that the sleeve is fully melted onto the cable. In accordance with some embodiments, the computer compares the measured diameter of a shielded cable to the changing diameter of a solder sleeve to determine when the solder sleeve has been fully melted. When the solder sleeve diameter reaches a preset specified threshold, the system sends a signal to remove and/or turn off the heat source.

The apparatus disclosed herein eliminates the necessity for an operator to actively monitor the solder sleeve during the melt process, freeing that operator to perform other useful tasks. The apparatus may also be adapted for use in an automated cable processing line. More specifically, the solder sleeve installation apparatus disclosed herein may be arranged on a benchtop or may be incorporated in an automated production line that includes a cable delivery system and a multiplicity of workstations accessible to the cable delivery system. In the automated production line, each workstation is equipped with a respective cable processing module (including hardware and software) that performs a respective specific operation in a sequence of operations designed to produce a shielded cable having a solder sleeve or dead end sleeve installed on one end of the cable. One of the workstations has the solder sleeve installation apparatus disclosed in detail below.

Although various embodiments of methods and apparatus for installing a sleeve on a cable will be described in some detail below, one or more of those embodiments may be characterized by one or more of the following aspects.

One aspect of the subject matter disclosed in detail below is an apparatus for installing a sleeve on a cable, the apparatus comprising: a heater capable of producing enough heat to melt the object in a heating zone; a photoelectric sensor directed toward the heating zone and configured to transmit light and acquire sensor data indicating transitions between transmitted light being obstructed and not being obstructed; and a computer system operatively coupled to receive sensor data from the photoelectric sensor, the computer system being configured to compute a measured value of a dimension of the object using the sensor data and issue an alert signal if the measured value becomes equal to a target value corresponding to a fully melted object. In cases wherein the sleeve melting operation is automated, the computer system is operatively coupled to send heater control signals to the heater and is further configured to change a state of the heater so that the heater ceases producing heat in the heating zone in response to the measured value becoming equal to the target value.

Another aspect of the subject matter disclosed in detail below is a method for melting an object on a cable, the method comprising: (a) positioning an object on a cable in a heating zone; (b) using a heat source to produce enough heat in the heating zone to melt the object; (c) measuring a dimension of the object during melting; and (d) changing a state of the heat source so that the heat source ceases producing heat in the heating zone in response to the measured dimension becoming equal to a target dimension. In accordance with some embodiments, the method further comprises issuing an alert signal when the measured dimension becomes equal to the target dimension, wherein step (d) is performed by a human operator after the alert signal has been issued. In accordance with other embodiments, step (d) is performed by a computer system.

A further aspect of the subject matter disclosed in detail below is an apparatus for melting a sleeve on a cable, the apparatus comprising: cable supports positioned and configured to support a cable so that a sleeve placed around the cable is in a heating zone located between the cable supports; a heater positioned and configured to produce heat in the heating zone; a sensor directed toward the heating zone and configured to acquire sensor data that is a measure of a dimension of the sleeve; and a computer system operatively coupled to receive sensor data from the sensor, the computer system being configured to compute a measured value of the dimension of the sleeve using the sensor data and issue an alert signal if the measured value becomes equal to a target value corresponding to a fully melted sleeve.

Yet another aspect is a method for melting a sleeve on a cable, the method comprising: placing a sleeve on a cable; supporting the cable between a pair of cable supports positioned on opposite sides of a heating zone, the cable being supported in a position so that the sleeve is in the heating zone; using a heat source to produce heat in the heating zone; acquiring sensor data that is a measure of a dimension of the sleeve during melting; computing a measured value of the dimension of the sleeve using the sensor data; and issuing an alert signal if the measured value becomes equal to a target value corresponding to a fully melted sleeve.

Other aspects of methods and apparatus for installing a sleeve on a cable are disclosed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, functions and advantages discussed in the preceding section may be achieved independently in various embodiments or may be combined in yet other embodiments. Various embodiments will be hereinafter described with reference to drawings for the purpose of illustrating the above-described and other aspects. None of the diagrams briefly described in this section are drawn to scale.

In addition, the depiction of shielded cabling in the drawings has been simplified by assuming that the cable being viewed in the drawing has a circular outer profile of constant diameter along its length, although some shielded cabling having a jacket that conforms to the undulations in the electrical wires has an outer profile that varies along its length.

FIG. 1 is a diagram representing and identifying components of an automated system for performing respective operations on an end of a cable at a plurality of cable processing modules in accordance with one embodiment.

FIGS. 2A and 2B are diagrams representing top views of a cable-carrying, drive wheel-equipped pallet in two states: when the drive wheel is separated from an idler wheel (FIG. 2A) and when the drive wheel is in contact with the idler wheel (FIG. 2B).

FIG. 3 is a diagram representing a top view of the pallet depicted in FIG. 2B in a position adjacent a cable processing module where a tip of the cable is positioned in front of a funnel.

FIG. 4A is a diagram representing a side view of a cable-carrying, drive wheel-equipped pallet in a position adjacent a cable processing module.

FIG. 4B is a diagram representing a top view of the apparatus depicted in FIG. 4A.

FIG. 5 is a block diagram identifying components of a cable processing workstation in accordance with one embodiment.

FIG. 6 is a diagram representing a side view of a portion of a cable having an unjacketed end with an exposed shield that has been trimmed.

FIG. 7A is a diagram representing a side view of the solder sleeve having a pre-installed ground wire.

FIG. 7B is a diagram representing a side view of the solder sleeve depicted in FIG. 7A when overlying a portion of the cable that includes exposed shielding.

FIG. 7C is a diagram representing a side view of the solder sleeve depicted in FIG. 7A when installed by melting on the portion of the cable that includes exposed shielding.

FIGS. 8A and 8B are diagrams representing a side view of a portion of a sleeve-cable assembly having an “out front” solder sleeve before (FIG. 8A) and after melting (FIG. 8B).

FIGS. 9A and 9B are diagrams representing a side view of a portion of a sleeve-cable assembly having an “out back” solder sleeve before (FIG. 9A) and after melting (FIG. 9B).

FIG. 10A is a diagram showing a view of a portion of an end effector in accordance with one embodiment having two pairs of prongs gripping a solder sleeve.

FIG. 10B is a diagram showing a view of an end effector having a pair of sleeve gripper fingers and respective pairs of prongs attached to the gripper fingers.

FIG. 11 is a diagram showing a view of some components of a cable processing module including a set of three open-top funnels designed to thread cables with exposed shields through solder sleeves of different sizes.

FIG. 12 is a diagram showing a view of the components depicted in FIG. 11, with the addition of an end effector having fingers that grip the sleeve of the sleeve-cable assembly and a cover plate that covers the open top of the central funnel.

FIG. 13 is a diagram showing a view of the components depicted in FIG. 11 at an instant in time after a solder sleeve has been placed on a funnel extension and a cable has been passed through the open-top funnel and the solder sleeve as part of an automated solder sleeve installation operation.

FIG. 14 is a diagram representing a view of an apparatus for melting a solder sleeve onto a portion of a cable having exposed shielding using hot air as part of an automated solder sleeve installation operation.

FIG. 15 is a diagram representing a view of an infrared heater in position to melt a solder sleeve onto a portion of a cable having exposed shielding as part of an automated solder sleeve installation operation.

FIG. 16 is a flowchart identifying steps of a method for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment.

FIG. 17 is a block diagram identifying some components of an automated system for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment.

FIG. 18 is a flowchart identifying steps of a method for controlling a system having a plurality of workstations for performing a sequence of operations for installing a solder sleeve on an end of a cable in accordance with one embodiment.

FIG. 19 is a diagram representing a view of an infrared heater in position to melt a solder sleeve onto a portion of a cable being supported by a pair of cable supports. The dashed arrows in FIG. 19 represent respective beams of light which are used to measure a dimension of the sleeve during melting.

FIG. 20 is a diagram representing a view of a laser scan micrometer in position to measure a dimension of a sleeve on a cable.

FIG. 21 is a diagram identifying components of a laser scan micrometer.

FIG. 22 is a flowchart identifying steps of a method for using active dimensional analysis during a manual solder sleeve installation procedure.

Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals.

DETAILED DESCRIPTION

Illustrative embodiments of methods and apparatus for installing a sleeve on a cable are described in some detail below. However, not all features of an actual implementation are described in this specification. A person skilled in the art will appreciate that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

For the purpose of illustration, various embodiments of an apparatus for installing a solder sleeve on a shielded cable will now be described. Such an apparatus may be included in cable processing equipment at one or more modules at separate workstations in a fully automated production line or may be benchtop cable processing equipment (e.g., equipment mounted on a workbench and accessible to a human operator).

As used herein, the term “tip of a cable” means a portion of a cable exposed by cutting the cable in a cross-sectional plane. As used herein, the term “end of a cable” means a section of cable having a tip and a length of cable extending from the tip. For example, removal of a length of the jacket of a cable that extends to the cable tip creates an end of the cable in which the shielding is exposed.

FIG. 1 is a diagram representing and identifying components of a system 110 for performing respective operations on an end of a cable 10. The system 110 includes a cable delivery system 60 cable delivery system 60. For example, the cable delivery system 60 may take the form of a conveyor system with locating modules (not shown in FIG. 1). Locating modules are components for positioning pallets in preparation for performance of an automated operation. In accordance with the embodiment depicted in FIG. 1, the cable delivery system 60 cable delivery system 60 includes a conveyor track 62 in the form of an endless belt or chain. The entire conveyor track 62 is continuously moving. In alternative embodiments, the cable delivery system 60 is not endless, in which case pallets 64 arriving at the end of a linear conveyor track may be transported to the starting point by other means. In accordance with alternative embodiments, the cable delivery system 60 may be a gantry robot or a robotic arm.

The system 110 depicted in FIG. 1 further includes a multiplicity of automated workstations situated adjacent to and spaced at intervals along the conveyor track 62. Each workstation is equipped with hardware that performs a respective specific operation in a sequence of operations designed to produce a shielded cable 10 having a solder sleeve 12 installed on one end of the cable 10. The locating modules (not shown in FIG. 1) of the system 110 are used to lift each pallet 64 off of the conveyor track 62 when an operation has to be performed at a workstation on the coil carried by that pallet 64 and later place the pallet 64 back on the conveyor track 62 after the operation has been completed so that the pallet 64 can move onto the next workstation.

Each pallet 64 carries a respective coil of cable 10. Pallets 64 move intermittently along the conveyor track 62 in the forward direction indicated by the arrows in FIG. 1, advancing from one automated workstation to the next and then stopping. (This aspect of the cable delivery system 60 will be referred to hereinafter as “pulsing”.) A respective bar code reader (not shown in the drawings) is mounted on the side of the conveyor track 62 opposite to each workstation. Each pallet 64 has a bar code printed on a forward side portion thereof. When the bar code reader detects the arrival of a pallet 64, each workstation has a respective controller (e.g., a computer programmed to execute computer numeric control (CNC) commands) that activates the cable processing module of that workstation to begin an automated cable processing operation.

Each shielded cable 10 to be processed is carried on a respective pallet 64 that is conveyed along the conveyor track 62. The pallets 64 pulse down the conveyor track 62 and the end of each shielded cable 10 is inserted into a series of cable processing modules in sequence, each cable processing module including cable processing equipment for performing successive operations of a solder sleeve installation process. In accordance with the embodiment depicted in FIG. 1, the cable processing modules include the following: a de-reeler module 32, a laser marker 34, a coiler module 36, a cable tip positioning module 38, a laser scoring module 40, a jacket slug pulling module 42, a shield trimming module 44, a shield trim inspection module 46, two solder sleeve installation modules 52 and 54 (also referred to herein as “solder sleeve pick, place and melt modules”), and a ground wire detection module 58. In accordance with the proposed implementation depicted in FIG. 1, there are three open positions where cable processing does not occur. These open positions, where a pallet may be parked, are referred to herein as buffers 48, 50 and 56.

As indicated in FIG. 1 by triangle symbols, some of the workstations include funnels 22 which center the inserted end of the cable 10 in the cable processing equipment at the respective workstation. Other workstations, such as the workstation where the cable tip positioning module 38 is located, do not have a funnel. The workstations where the two solder sleeve installation modules 52 and 54 are located have open-top funnels 170, which also guide the end of the cable 10, but differ in structure from the funnels 22 in that the cable may be lifted vertically out of the open-top funnel 170 upon completion of the solder sleeve melting operation. In accordance with alternative embodiments, split funnels may be used.

Each of the automated cable processing operations identified in FIG. 1 will now be briefly described in some detail. The respective cable processing modules will be described in the order in which the respective cable processing operations are performed on one cable.

The starting material is a continuous length of multi-conductor shielded cable of a particular type wound on a reel. The de-reeler module 32 de-reels the continuous length of cable and then cuts the cable to a specified length, which length of cable will be referred to hereinafter as “cable 10”. Preferably a multi-spool de-reeler is used so that multiple cable types can be selected for processing off of a single machine. For each length of cable 10, the laser marker 34 laser marks the outer jacket 2 of the cable 10 with pertinent information (bundle number, wire number, gauge).

The coiler module 36 receives each length of cable 10 from the de-reeler module 32 and laser marker 34 and coils the cable 10. This creates a repeatable configuration for the cable that is easy to transport and maintain as it goes through the system. The coiler module 36 coils cables 10 and applies a sticker label. This label contains information about the cable (airplane effectivity, bundle, dash, wire identification, etc.), as well as a bar code. In accordance with one proposed implementation, the coiler module 36 ensures that one end of the coiled cable 10 has seven inches of “free” cable.

The coil of cable 10 is taken off of the coiler and placed on a pallet 64. The pallet 64 is then transferred from the coiler module 36 to the cable tip positioning module 38. This may be done manually by an operator or automatically by a robotic end effector (or some other apparatus).

The cable tip positioning module 38 serves to initially position the tip of the cable 10 at a preset cable tip position prior to the cable 10 continuing through the system 110. It is the first “stop” along the conveyor track 62, and is where the cable 10 is first placed onto the system. The preset cable tip position is selected to prevent the cable end from being too long as it travels along the conveyor track (hitting other objects within the system, being crushed or otherwise damaged, etc.). After the cable tip positioning module 38 has positioned the cable tip 10 b at the preset cable tip position, the pallet 64 leaves the cable tip positioning module 38.

In accordance with the embodiment depicted in FIG. 1, after the cable tip positioning module 38 has positioned the cable tip 10 b, the pallet 64 moves to the laser scoring module 40. The workstation where the laser scoring module 40 is located also includes a funnel 22 for guiding a cable 10 into the cable processing equipment of the laser scoring module 40. The laser scoring module 40 lightly scores the jacket 2 of the cable 10 along a score line 3 which extends circumferentially in a plane that intersects an annular region of the jacket 2. The presence of the laser score line 3 prepares the applicable segment of jacket 2 (hereinafter “the jacket slug 2 a”) to be removed.

After the laser scoring module 40 has scored the jacket 2 of the cable 10, the pallet 64 moves to the jacket slug pulling module 42. The workstation where the jacket slug pulling module 42 is located also includes a funnel 22 for guiding a cable 10 into the cable processing equipment of the jacket slug pulling module 42. The jacket slug pulling module 42 removes the jacket slug 2 a to reveal the shield 4 in the unjacketed portion of the cable 10. An electrical continuity shield sensor (not separately depicted in FIG. 1) may be integrated with the jacket slug pulling module 42 to detect that the jacket slug 2 a was removed prior to retracting the cable 10 from the jacket slug pulling module 42.

After the jacket slug pulling module 42 has pulled off the jacket slug 2 a of the cable 10, the pallet 64 moves to the shield trimming module 44. The workstation where the shield trimming module 44 is located also includes a funnel 22 for guiding a cable 10 into the cable processing equipment of the shield trimming module 44. The shield trimming module 44 trims off a portion of the exposed portion of the shield 4 to reveal respective portions of the wires 6 and 8 of the cable 10. In accordance with one proposed implementation, the shield trimming module 44 trims the shield 4 of the cable 10 about 0.25″ from the edge of the jacket 2.

After the shield trimming module 44 has trimmed the shield 4 of the cable 10, the pallet 64 moves to the shield trim inspection module 46. The workstation where the shield trim inspection module 46 is located also includes a funnel 22 for guiding a cable 10 into the cable processing equipment of the shield trim inspection module 46. The shield trim inspection module 46 performs a quality check of the trimmed shield using a vision inspection system. The quality check ensures that the shield 4 meets the specifications for the particular type of cable 10 (e.g., shield strands are not too long or too short, not damaged, etc.) prior to installing a solder sleeve 12.

After the shield trim inspection module 46 has inspected the trimmed shield 4 of the cable 10, the pallet 64 moves to one of two solder sleeve installation modules 52 and 54. The workstations where the solder sleeve installation modules 52 and 54 are located also include an open-top funnel 170 for guiding a cable 10 into the cable processing equipment of the solder sleeve installation modules 52 and 54. The solder sleeve installation modules 52 and 54 are configured to install a solder sleeve 12 with a ground wire 14 onto the cable 10 using automated picking, placing and melting operations. Each solder sleeve installation modules preferably includes a sensor system that actively measures the diameter of the cable with solder sleeve and monitors the shrinking diameter of the solder sleeve during the melting process using dimensional analysis. The sensor system activates or deactivates the heating element based on the dimensional analysis of the solder sleeve; this may also control the transportation of the cables through the device.

Solder sleeves are limited in how quickly they are able to fully melt without burning due to their design and materials. The type of heat source used (hot air, infrared) has no significant impact on the melt time. This creates a bottleneck on the moving line, due to the fact that all processes prior to the solder sleeve melting operation take much less time to complete, and limits the lowest achievable cycle time of the overall line.

In accordance with one proposed implementation, two cables 10 may have solder sleeves installed concurrently using the two solder sleeve installation modules 52 and 54. After the solder sleeve 12 has been installed on the cable 10 by one of the solder sleeve installation modules 52 and 54, the pallet 64 moves to ground wire detection module 58. The workstation where the ground wire detection module 58 is located also includes a funnel 22 for guiding a cable 10 into the cable processing equipment of the ground wire detection module 58. The ground wire detection module 58 detects the ground wire 14 of the solder sleeve 12. This may be done through physical sensing or an electrical continuity test, all of which are commercially available off the shelf.

As seen in FIG. 1, the cable delivery system 60 includes multiple pallets 64 that travel on the conveyor track 62, each pallet 64 carrying a respective coil of cable 10. In accordance with some embodiments, the apparatus on the pallet 64 includes a pair of cable-displacing wheels (e.g., a motor-driven drive wheel and a spring-loaded idler wheel that is movable between positions that are respectively in contact with and not in contact with the motor-driven drive wheel) designed to push and pull cables through a cable-guiding funnel which centers the cable for insertion into the cable processing equipment. The ability of the drive and idler wheels to move apart enables wires or cables of varying diameters and cross-sectional profiles to be placed between the drive and idler wheels. This apparatus is intended to be universal, i.e., to be able to be used on any equipment (including benchtop equipment) that processes wires and/or cables. Additionally, a user would be able to define the amount (length) of cable that is fed into the equipment, depending on the cable that is to be processed and its related requirements.

Some features of a pallet 64 in accordance with one embodiment will now be described with reference to FIGS. 2A and 2B; other features of the pallet 64 not shown in FIGS. 2A and 2B will be described later with reference to other drawings. As seen in FIGS. 2A and 2B, each pallet 64 has a drive wheel 16 and an idler wheel 18 which are rotatably coupled to the pallet 64. The drive wheel 16 and idler wheel 18 are preferably padded with a compliant material capable of conforming to different cross-sectional profiles (e.g., single-versus multi-conductor cable). An encoder may be attached to one or both of the wheels in order to more accurately track how far the cable 10 has been moved by the wheels. The encoder tracks the “distance traveled” of a drive roller by multiplying the number of rotations by the circumference of the drive wheel 16.

The pallet 64 also includes a corral 66 in the form of a curved wall that is contoured to guide the cable end 10 a toward the drive wheel 16 and idler wheel 18. The drive wheel 16 and idler wheel 18 cooperate to move the cable end 10 a into and out of an adjacent cable processing module 30. FIGS. 2A and 2B show the pallet 64 in two states: when the drive wheel 16 is separated from the idler wheel 18 (FIG. 2A) and when the drive wheel 16 is in contact with the idler wheel 18 (FIG. 2B).

As seen in FIG. 2A, the free end 10 a of the cable 10 is placed between the drive wheel 16 and idler wheel 18 so that the cable tip 10 b is at a position in front of the nip, while the cable 10 is intersected by a vertical scanning plane 11 (indicated by a dashed line in FIGS. 2A and 2B) located at a known position. This known position is a known distance from a preset cable tip position. Although FIG. 2A shows the cable tip 10 b located beyond the vertical scanning plane 11, the starting position of the cable tip 10 b may be either beyond or short of the vertical scanning plane 11.

The force holding the idler wheel 18 apart from drive wheel 16 is then discontinued, following which the idler wheel 18 is urged by springs (not shown in FIGS. 2A and 2B) into contact with the drive wheel 16, thereby forming a nip that squeezes the shielded cable 10. As will be described in further detail below, the drive wheel 16 and idler wheel 18 are configured so that sufficient frictional forces are produced that enable the shielded cable 10 to be either pushed or pulled through the nip depending on the directions of wheel rotation. Upon detection of the presence of the cable tip 102 b at a position beyond the vertical scanning plane 11, the drive wheel 16 and idler wheel 18 are rotated in a cable pulling direction to cause the cable end 10 a to retract and the cable tip 10 b to move toward the vertical scanning plane 11. Conversely, if the cable tip 102 b were at a position short of the vertical scanning plane 11 (hereinafter “scanning plane 11”), the drive wheel 16 and idler wheel 18 would be rotated in a cable pushing direction to cause the cable end 10 a to extend and the cable tip 10 b to move toward the scanning plane 11. The remainder of the description of FIGS. 2A and 2B will discuss the case wherein the cable end 10 a is initially placed in a position such that the cable tip 102 b is beyond (not short of) the scanning plane 11

The movement of the cable tip 10 b is monitored by detecting when the cable tip 10 b reaches the scanning plane 11. This is accomplished by a photoelectric sensor (not shown in FIGS. 2A and 2B, but see photoelectric sensor 28 in FIGS. 4A and 4B) mounted to the pallet 64 and configured to function as a light gate. In accordance with some embodiments, the photoelectric sensor 28 is configured to act as a light gate that detects when there is no portion of the cable 10 blocking a light beam propagating in the scanning plane 11 from one side of the light gate to the other side. FIG. 2B shows the state wherein the cable tip 10 b is aligned with the scanning plane 11 following retraction of the cable end 10 a. In response to the photoelectric sensor 28 detecting a transition between a state of light being interrupted (e.g., blocked) in the scanning plane 11 and a state of light not being interrupted, the photoelectric sensor 28 issues a cable tip position signal indicating the transition between interruption and no interruption of transmitted light at the scanning plane. In response to issuance of the cable tip position signal, the computer of the cable positioning module activates a motor (not shown in FIGS. 2A and 2B, but see motor 72 in FIGS. 4A and 4B) to rotate the drive wheel 16 an amount and in a direction such that at the end of the rotation, the cable 10 does not extend beyond a preset cable tip position. This preset cable tip position is a known distance from the scanning plane 11. The preset cable tip position may be selected to ensure that the cable tip 10 b may travel along the conveyor track 62 with sufficient clearance to avoid damage from stationary objects.

The cable tip positioning module 38 includes a computer system (not shown in FIG. 3. The cable tip positioning signal from the photoelectric sensor 28 is received by the computer 162 a. The computer 162 a is configured to de-activate the motor 72 that drives rotation of the drive wheel 16 (thereby ceasing driving rotation of the drive wheel 16 in the cable pulling direction) after a predetermined angular rotation of the drive wheel 16 subsequent to issuance of the cable tip position signal. In other words, there is a time delay during which the drive wheel 16 and idler wheel continue to move the cable end 10 a, causing the cable tip 10 b to move from the current position depicted in FIG. 2B (in this instance, corresponding to the position of the scanning plane 11) to a preset cable tip position a short distance (e.g., 0.5 inch) from the scanning plane 11. More specifically, the computer 162 a is configured to start a count of pulses output by a rotation encoder (mounted on the drive wheel shaft 88 or the motor output shaft, for example) in response to issuance of the cable tip position signal and then de-activate the motor 72 in response to the count reaching a specified value representing the distance separating the preset cable tip position from the scanning plane 11.

In accordance with an alternative embodiment, the preset cable tip position and the position of the scanning plane may be one and the same, provided that the movement of the cable 10 can be stopped precisely at the instant in time when the photoelectric sensor 28 issues the cable tip position signal.

The above-described cable tip positioning process ensures that the cable tip 10 b is in a repeatable position and does not extend beyond the preset cable tip position prior to continuing down the conveyor track 62. At this juncture, the conveyor track 62 pulses forward, causing the pallet to move to the next workstation.

FIG. 3 is a diagram representing a top view of the pallet 64 in a position adjacent a cable processing module 30. The apparatus includes a drive wheel 16 and an idler wheel 18 configured for driving the cable 10 forwards or backwards between the wheels and a funnel 22 capable of capturing the cable end 10 a. While the wheels control the motion of the cable 10, the funnel 22 serves to center the cable 10 for insertion into the cable processing equipment. This function will be used to insert and position the cable 10 into different modules for processing as the cable 10 is transported through the system.

More specifically, the cable tip 10 b is positioned in front of a funnel 22 that is configured to center a cable end 10 a as it is fed into the cable processing equipment 24 of a cable processing module 30. Each cable processing module 30 is equipped with a funnel 22 (or an open-top funnel not shown) and a photoelectric sensor (not shown in FIG. 3, but see photoelectric sensor 28 in FIG. 5) for detecting the presence of the cable tip 10 b in a scanning plane 11 (indicated by a dashed line in FIG. 3). It is important that the interior surface of the funnel 22 be smooth and devoid of any rough or sharp edges that may abrade, tear, or otherwise damage the cable 10. Preferably the funnel 22 is made of a thermoplastic material with a low coefficient of friction to prevent the funnel 22 from slowing the cable 10 down as it is moved by the drive wheel 16 and idler wheel 18 (preventing slippage). The funnel 22 may be configured in different ways. In lieu of a basic hole on the exit side of the funnel 22 (small diameter side), the funnel 22 may have a flexible piece of material featuring an X-shaped cut centered within the funnel 22. This helps to provide a repeatable, centered position for the cable 10 as it is either pushed forward or pulled back. It also permits the cable-guiding funnel to accurately center cables with varying diameters and cross sectional profiles. Other cable-guiding funnels may also be split and/or feature an open top.

In accordance with some embodiments, each workstation includes a stationary motor (not shown in FIG. 3, but see motor 72 in FIGS. 4A and 4B). In accordance with one proposed implementation, the motor 72 is an electric stepper motor. The motor shaft speed will control how fast the drive wheel rotates (the speed at which the end of the cable 10 is moved), as well as which directions the wheels rotate in. The motor 72 is configured to rotate either clockwise or counterclockwise.

In response to detection of the arrival of the pallet 64 at the cable processing module 30 by a pallet detector (not shown in FIG. 3, but see pallet detector 160 in FIG. 5), the motor 72 is operatively coupled to the drive wheel 16. Subsequently the motor 72 is activated to drive the drive wheel 16 to rotate in the cable pushing direction. The shaft of the motor 72 is optionally equipped with a rotation encoder 73 (see FIG. 5) for determining the angular rotation of the drive wheel 16. During rotation of the drive wheel 16 in the cable pushing direction, the rotation encoder 73 tracks the rotation of the motor shaft to generate digital position information representing the length of cable 10 which has been fed past the scanning plane 11.

When a pallet 64 stops at the cable processing module 30, the drive wheel 16 and idler wheel 18 are driven to rotate in a cable pushing direction to cause the cable tip 10 b to pass the photoelectric sensor 28, through the funnel 22, and into the cable processing equipment 24. Once the photoelectric sensor 28 is triggered, the rotation encoder 73 will begin to record the position of the cable tip 10 b. This provides a way to track the inserted length of the cable 10 in real time, and subsequently cause the motor 72 to stop once the correct length of cable 10 has been fed into the cable processing equipment 24. The drive wheel 16 and idler wheel 18 continue to rotate in the cable pushing direction until a specified length of cable 10 has been inserted into the cable processing equipment 24 via the funnel 22.

FIG. 4A is a diagram representing a side view of a pallet 64 in a position adjacent a cable processing module 30, which pallet 64 is equipped with a reelette 26 for holding a coil of cable 10 and a drive wheel 16 (not visible in FIG. 4A) for feeding an end of the cable 10 into the cable processing module 30 in accordance with a further embodiment. FIG. 4B shows a top view of the pallet 64 in a position adjacent the cable processing module 30. The pallet 64 further includes a cable positioning mechanism 19 that is controlled to place the tip 10 b of the cable 10 at a repeatable position at each cable processing module 30.

As seen in FIG. 4A, the cable processing module 30 is mounted on a stationary plate 68. A stanchion 70 is affixed to the stationary plate 68 in a position in front of the cable processing module 30. A motor 72 is mounted to a base 70 a of the stanchion 70. The motor 72 has an output shaft 74 which drives rotation of the drive wheel 16 (not visible behind the idler wheel 18 in FIG. 4A). In addition, a photoelectric sensor 28 is mounted to an upright portion 70 b of the stanchion 70. The photoelectric sensor 28 is placed at an elevation such that the photoelectric sensor 28 is able to detect the cable tip 10 b when it passes through a scanning plane 11 (indicated by a dashed line in FIGS. 4A and 4B) during cable pushing.

In accordance with the embodiment depicted in FIG. 4A, each coil of cable 10 is individually wound onto its own reelette 26, which reelette 26 is supported by and rotatably coupled to the pallet 64. The corral 66 (see in FIGS. 2A-2C) is not shown in FIG. 4A so that the reelette 26 is visible. The reelette 26 has an opening (not shown in FIG. 4A) on its outer periphery through which a portion of the cable 10 (including cable end 10 a) passes. FIG. 4A shows a state in which the cable end 10 a is disposed between rotating drive wheel 16 and idler wheel 18 (drive wheel 16 is located directly behind the idler wheel 18 and not visible in FIG. 4A), while the cable tip 10 b is moving in a direction (indicated by an arrow in FIG. 4A) toward the cable processing module 30.

FIG. 4B shows a top view of the pallet 64 when the cable tip 10 b is positioned at a scanning plane 11 of the photoelectric sensor 28. The double-headed straight arrow superimposed on the idler wheel 18 indicates that the idler wheel 18 is laterally movable away from and toward the drive wheel 16. Meanwhile the curved arrows superimposed on the drive wheel 16 and idler wheel 18 are intended to indicate that the drive wheel 16 and idler wheel 18 are rotating in a cable pushing direction. At the instant of time depicted in FIG. 4B, the cable tip 10 b is positioned at the scanning plane 11 and is moving toward the cable processing module 30.

The cable processing module 30 includes a computer (not shown in FIGS. 4A and 4B) FIG. 5 is a block diagram identifying some components of a cable processing workstation in accordance with one embodiment. As previously described, each cable processing workstation includes a funnel 22 and cable processing equipment 24 (not shown in FIG. 5, but see FIG. 3). The cable processing workstation further includes a computer 162 that is configured to control various actuators and motors by executing pre-programmed sequences of machine control commands, such as computer numerical control commands. FIG. 5 depicts an example wherein the computer 162 is programmed to send control signals to various electrically controlled valves 80 which may be opened to supply compressed air from a compressed air supply 82 to one or more of a multiplicity of pneumatic cylinders 84, 86 and 88. The pneumatic cylinders 84, 86 and 88 may be used to move various components of the cable processing equipment 24. In alternative embodiments, the pneumatic cylinders may be replaced by electric motors.

The cable processing workstation depicted in FIG. 5 further includes a motor 72 and a rotation encoder 73 operatively coupled to the output shaft 74 of the motor 72. The rotation encoder 73 generates pulses which the computer 162 is configured to count for the purpose of determining the number of degrees of motor output shaft rotation, which angular measurement in turns represents a distance traveled by the cable tip 10 b during that output shaft rotation. The computer 162 also receives sensor feedback from a photoelectric sensor 28 used to detect a cable tip position and a pallet detector 160 used to detect a pallet position. The computer 162 is configured to send commands to a motor controller 164 for controlling the motor 72 in accordance with feedback from photoelectric sensor 28, rotation encoder 73 and pallet detector 160.

The computer 162 of each cable processing module 30 is configured to perform the following operations: activate the motor 72 to drive rotation of the drive wheel 16 in a cable pushing direction to cause a specified length of cable 10 to be inserted into the cable processing equipment 24; activate the cable processing equipment 24 to perform an operation on the inserted cable end 10 a; and activate the motor 72 to drive rotation of the drive wheel 16 in a cable pulling direction to cause the specified length of cable 10 to be removed from the cable processing equipment 24.

Each workstation comprises a rotation encoder 73 configured to output pulses representing the incremental angular rotations of an output shaft of the motor 72. The photoelectric sensor 28 is positioned and configured to issue a cable tip position signal indicating that interruption of transmitted light in the scanning plane 11 has started. In other words, the cable tip position signal is issued in response to the photoelectric sensor 28 detecting that a state of light not being blocked in the scanning plane 11 has transitioned to a state of light being blocked. The computer 162 is further configured to start a count of pulses output by the rotation encoder 73 in response to the cable tip position signal and then de-activate the motor 72 in response to the count reaching a specified value corresponding to a specific target length of cable 10 having been inserted in the cable processing equipment 24.

The photoelectric sensor 28 that detects the position of the cable tip 10 b in each cable processing module 30 may be of the same type as the photoelectric sensor 28 incorporated in the cable tip positioning module 38. For example, digital laser sensors of various types are suitable. Many adaptable options are available off the shelf, such as proximity sensors and vision sensors.

In accordance with some embodiments, the photoelectric sensor 28 used to detect cable tip position is of a type that is also capable of measuring the diameter of the cable 10 to ensure that false positives are not caused by fingers or other objects larger than the typical cable diameter. The diameter measurement may also be used to confirm that the cable 10 is of the type expected by the computer 162 of the cable processing module 30.

In accordance with one proposed implementation, the photoelectric sensor 28 is a laser sensor of the “position recognition” type (a.k.a. a laser scan micrometer). In a laser scanner of this type, a scanning laser beam is emitted from a scanning light beam transmitter 28 a, which scanning light beam scans in the scanning plane 11 and is then received by the light-detecting sensor 28 b. In accordance with one embodiment, the light-detecting sensor 28 b includes a linear array of light-detecting elements (e.g., a column of pixels in a charge coupled device). The area where the scanning laser beam is interrupted is identified clearly on the light-detecting sensor 28 b. This type of laser sensor may be used for in-line cable tip position detection or cable outer diameter measurement.

The computer 162 of the cable processing module 30 is further configured to perform the following operations: compute a length of an interruption in light received by the light-detecting sensor 28 b from the scanning light beam transmitter 28 a; compare the computed length of the interruption to reference data representing a diameter of the type of cable 10 to be processed; and issue an alert signal when a difference of the computed length of the interruption and the reference data exceeds a specified threshold.

In accordance with other embodiments, the above-described cable positioning system may be used to position the tip of the cable at multiple positions within any given processing module. Such feature allows multi-step processing within a single module. The tip of the cable, for example, could be positioned at multiple positions within the laser scoring module 40 to allow the laser to score the cable in multiple locations. For very long strip lengths (four inches for example) the cable could be laser scored every inch. The jacket slug pulling module 42 would then pull of each one-inch slug one at a time (again using multi-step insertion). Thus the jacket puller only needs to overcome pull-off friction forces for one inch of jacket instead of four inches of jacket.

Referring again to FIG. 1, after the jacket slug pulling module 42 has pulled off the jacket slug 2 a of the cable 10, the pallet 64 moves to the shield trimming module 44. The shield trimming module 44 incorporates equipment for trimming off a portion of the exposed portion of the shield 4 to reveal respective end portions of the wires 6 and 8 of the cable 10. After the shield trimming module 44 has trimmed the shield 4 of the cable 10, the pallet 64 moves to the shield trim inspection module 46 (see FIG. 1). The shield trim inspection module 46 performs a quality check of the trimmed shield using a vision inspection system.

FIG. 6 is a diagram representing a side view of a portion of a cable 10 having an unjacketed end with an exposed shield 4 that has been trimmed. The trimming of the shield 4 in turn exposes the wires 6 and 8 of the cable 10. The shield trim is inspected using a vision system that includes a camera system arranged to capture a 360-degree view of the trimmed shield and a computer programmed to analyze the captured images. More specifically, the computer is configured to determine whether excessive gaps are present in the exposed shield (e.g., caused by broken shield strands) or not. The evaluation system compares perceived gaps in the image with a maximum allowable gap value to ensure that the percentage of shield coverage is within the specified tolerance.

Shield coverage percentages below a specified minimum percentage of coverage indicate to the evaluation system that an unacceptable number of shield strands may be broken. The computer may also be configured to determine whether the length of the exposed shield on the cable is within an allowable range.

After the shield trim inspection module 46 has inspected the trimmed shield 4 of the cable 10, the pallet 64 moves to one of two solder sleeve installation modules 52 and 54 (see FIG. 1). The solder sleeve installation modules 52 and 54 are configured to install a solder sleeve 12 with a ground wire 14 onto the cable 10 using automated picking, placing and melting operations.

FIG. 7A is a diagram representing a side view of a typical solder sleeve 12 having a pre-installed ground wire 14. The solder sleeve 12 includes a sleeve 7 made of transparent, heat-shrinkable thermoplastic material. The internal diameter of the sleeve is greater than the outer diameter of the cable being processed. The solder sleeve 12 further includes a central solder ring 9 adhered to the inside of the sleeve 7 at a central position and a pair of thermoplastic sealing rings 13 a and 13 b.

FIG. 7B is a diagram representing a side view of the solder sleeve 12 depicted in FIG. 7A when placed in a position overlying a portion of a cable 10 having a jacket 2 and an unjacketed portion where the shield 4 is exposed. The exposed shield 4 is surrounded by the central solder ring 9, which when melted and then solidified will form an electrical connection between the shield 4 and the ground wire conductor strand 15. The sleeve 7 has not yet been melted.

FIG. 7C is a diagram representing a side view of the solder sleeve 12 depicted in FIG. 7A after the solder sleeve 12 has been melted on the cable 10.

As disclosed above, the solder sleeve installation module 52 and 54 (see FIG. 1) are each configured to install a solder sleeve 12 onto the end of a cable 10. The cable processing equipment of a solder sleeve installation module may be used to install a solder sleeve 12 (e.g., of the type described with reference to FIG. 7A) or a dead end sleeve made of electrical insulation material only. Solder sleeves are melted and shrunk onto an end of a cable; a dead end sleeve is shrunk without melting onto an end of a cable. Solder sleeves and dead end sleeves are separated by part number and distributed onto different vibration tables. (Vibration tables could be replaced with tape-and-reels or cartridges). If the solder sleeve is on a tape-and-reel or cartridge, the solder sleeve will be pushed out of the cavity (via pneumatic actuator, electric actuator, etc.) so that an end effector can grip it.

FIGS. 8A and 8B are diagrams representing a side view of a portion of a sleeve-cable assembly 1 a having an “out front” solder sleeve 12. The sleeve-cable assembly 1 a includes a solder sleeve 12 having a ground wire 14 that extends away from the jacket 2 of cable 10. The solder sleeve 12 is threaded onto the wires 6 and 8 until the solder sleeve 12 is in a position surrounding the exposed shield 4. As seen in FIG. 8A, the “out front” solder sleeve 12 also surrounds an end segment of the jacket 2 and unshielded portions of wires 6 and 8. FIG. 8A shows sleeve-cable assembly 1 a before the “out front” solder sleeve 12 is melted on the cable 10. FIG. 8B shows sleeve-cable assembly 1 a after the “out front” solder sleeve 12 has been melted on the cable 10.

FIGS. 9A and 9B are diagrams representing a side view of a portion of a sleeve-cable assembly 1 a having an “out back” solder sleeve 12. The sleeve-cable assembly 1 a includes a solder sleeve 12 having a ground wire 14 that extends toward the jacket 2 of cable 10. The solder sleeve 12 is threaded onto the wires 6 and 8 until the solder sleeve 12 is in a position surrounding the exposed shield 4. FIG. 9A shows sleeve-cable assembly 1 a before the “out back” solder sleeve 12 is melted on the cable 10. FIG. 9B shows sleeve-cable assembly 1 a after the “out back” solder sleeve 12 has been melted on the cable 10.

At the start of a solder sleeve installation procedure, a robotic end effector is controlled to move to whichever one of a plurality of vibration tables (or other solder sleeve storage devices) has the correct type of solder sleeve 12 to be installed on the cable 10. The robotic end effector picks up a solder sleeve and carries it to the apparatus depicted in FIGS. 11-14. The robotic end effector has a pair of gripper fingers designed to grip a particular type of solder sleeve. The robotic end effector may be integrated onto a robotic arm or gantry with a vision system that recognizes the solder sleeve, thereby enabling the robot arm to be properly aligned when attempting to pick up the sleeve with a predetermined pigtail orientation. Pick and place vision systems are commercially available off the shelf and could be adapted to grip a particular solder sleeve 12.

FIG. 10B is a diagram showing a view of an end effector 108 having a pair of gripper fingers 112 and 114 and respective pairs 116 and 118 of prongs (or claws) attached to the gripper fingers 112 and 114 respectively for forming a sleeve gripper 111. FIG. 10A is a diagram showing a view of the two pairs 116 and 118 of prongs of the sleeve gripper 111 gripping a solder sleeve 12. The insulation rings 13 a and 13 b on each end of the solder sleeve 12 have a larger outer diameter than the rest of the solder sleeve 12. When the prongs 116 and 118 close over the portions of the solder sleeve 12 between the insulation rings 13 a, 13 b and the central solder ring 9, it is impossible for the insulation rings 13 a and 13 b to slip/pass through the opening between opposing prongs, thus making it impossible for the solder sleeve 12 to be able to inadvertently slip out of the sleeve gripper 111.

In one embodiment, the prongs 116 and 118 of the gripper fingers 112 and 114 are designed to cover or shield as little surface area of the solder sleeve 12 as possible. By maximizing the exposed surface area, it would be possible to apply heat to the solder sleeve 12 and perform the melt process while still gripping the solder sleeve 12 with the sleeve gripper 111. This would ensure that the solder sleeve 12 does not inadvertently become misaligned or move out of place prior to the heat application. This would also require that the prongs 116 and 118 be fabricated from a heat-resistant or metal material.

The robotic end effector 108 may be designed to pick and place solder sleeves or dead end sleeves. The end effector 108 is intended to be used as a part of a solder sleeve pick, place and melt module 52 or 54 that has been integrated into a fully automated system.

The prongs 116 and 118 of the gripper fingers 112 and 114 make contact with and grip the solder sleeve 12. The gripper fingers 112 and 114 may be attached to a pick-and-place air cylinder or some other device capable of moving gripper fingers 112 and 114 together and apart. The prongs 116 and 118 are designed to be able to hold solder sleeves of different sizes. In some in cases, solder sleeve parts may be constructed using large tolerance values; thus in actuality may vary in diameter, length, etc. The sleeve gripper 111 is designed to contact and grip the solder sleeve 12 between the central solder ring 9 and the insulating rings 13 a, 13 b, regardless of solder sleeve size thus avoiding the solder sleeve 12 from slipping out. The solder sleeve may have an indent in that space and can be held from it as shown in FIG. 10A. The opposing pairs of prongs 116 and 118 have semi-circular cutouts which prevent the solder sleeve 12 from being crushed and center the solder sleeve 12 within the sleeve gripper 111 for accurate placement during the installation process. The prongs 116 and 118 should be made of a rigid, heat-resistant material. Examples include aluminum, steel, etc.

In accordance with various proposed embodiments, the solder sleeves 12 will be separated by part number and located on reels of tape, in cartridges, or on vibration tables. The end effector 108 will be able to pick up a solder sleeve 12 from any of these configurations. Vibration tables are flat surfaces that vibrate to shift products from the end of the table (where they are loaded) to the front. In the case of solder sleeves carried by a carrier tape wound on a reel, the solder sleeves would be extracted from the cavity prior to gripping with the gripper fingers (using an underside actuator, gravity, etc.). In the case of a cartridge loaded with solder sleeves, a solder sleeve would need to be extracted from a cavity prior to gripping with the gripper fingers.

The end effector may be adapted for coupling to a robotic arm or a gantry robot. A gantry robot consists of a manipulator mounted onto an overhead system that allows movement across a horizontal plane. Gantry robots are also called Cartesian or linear robots. The robotic arm may be part of a robot having multi-axis movement capabilities. The robot includes one or more positional sensors (not shown) at, or otherwise associated with, each of the pivots that provide positional data (X, Y, and Z in three-dimensional space) to the data acquisition system for accurately locating the solder sleeves. An example of a robot that could be employed with the end effector 108 shown in FIG. 10A is robot Model KR-150 manufactured by Kuka Roboter GmbH (Augsburg, Germany), although any robot or other manipulator capable of control the position of the end effector 108 in the manner disclosed herein. The term “gantry/robot arm” will be used herein to mean a robot of either type having a robot controller configured to move and control the end effector 108 to perform the solder sleeve pick and place operations disclosed herein.

The sleeve gripper 111 will be used as a part of an end effector within the solder sleeve pick, place and melt module. The end effector 108 picks up a solder sleeve 12, places it over the prongs of a funnel 170 to partially encase them, and waits for the cable 10 to be passed through the funnel 170 and the solder sleeve 12. Once the cable 10 is through, the end effector 108 moves back to position the solder sleeve 12 over the desired area of cable 10. In accordance with embodiment, the desired area includes the exposed portion of the trimmed shield 4, an adjacent portion of the jacket and adjacent portions of the wires 6 and 8. The end effector 108 then releases the solder sleeve 12 and moves out of the way of the heating elements, which close over the solder sleeve 12 and melt the sleeve in place on the cable 10. In another embodiment, the end effector 108 does not release the solder sleeve and instead remains in place to hold the sleeve and cable stationary during the heating process. The heating elements are moved in position and then activated to heat the solder sleeve 12 while the prongs 116 and 118 hold the solder sleeve.

This end effector 108 enables the solder sleeve installation process to be fully automated. By automating this process, risks associated with the current manual process (repeatable quality, ergonomic issues, slower cycle times) are eliminated.

The cable processing equipment at each solder sleeve installation module 52 and 54 further comprises a set of funnels 170 (see FIG. 1) designed to accommodate shielded cables before and after a solder sleeve has been installed onto the cable. These funnels not only serve to guide the cable movement, but also to protect the exposed shielding of the cable as the cable 10 is fed through the solder sleeve 12 and positioned such that the exposed shield 4 is surrounded by the solder sleeve 12.

Once a solder sleeve 12 is installed onto a cable 10 on the intended area, the overall diameter of the combination of the cable 10 and solder sleeve 12 (sleeve-cable assembly 1 as shown later in FIG. 16A) is thus larger in diameter at that area than cable 10 originally. To the extent that the narrowest point along the open-top funnel 170 has been sized to match the outer diameter of the cable 10, a cable 10 with an installed solder sleeve 12 is unable to pass through the open-top funnel 170 for the purpose of exiting the solder sleeve installation module 52 or 54. To remove this obstacle, an “open top” funnel 170 has been designed in which a slot (hereinafter “opening 76”) was created in the top portion of each funnel 170. Such a slot 76 enables funnel 170 to accommodate changes and variations to the cable exterior size as it undergoes modifications through sleeve installation.

FIG. 11 is a diagram showing a view of some components of a solder sleeve installation module including a set of three open-top funnels 170 a-170 c designed to thread cables with exposed shields through solder sleeves of different sizes. The openings 76 a-76 c formed in the top portions of the open-top funnels 170 a-170 c enable removal of the cable 10 from the funnel after a solder sleeve 12 has been installed. The open-top funnels 170 a-170 c are mounted on a sliding plate 176 that is capable of sliding side to side to place a correct open-top funnel. As depicted in FIG. 12, an open-top funnel 170 b is placed in front of a notch 175 b of a cable guide block 175. The cable guide block further includes a guide surface 175 a for guiding the end of the cable 10 into the notch 175 b during cable insertion.

The funnel system further includes multiple funnel extensions 172 a-172 c. The plastic open-top funnels 170 a-170 c are effectively extended by attaching respective funnel extensions 172 a-172 c. Alternatively, the funnel extensions 172 a-172 c may be integrally formed with the respective open-top funnels 170 a-170 c. Each of the funnel extensions 172 a-172 c may terminate in a pair of prongs 78 a and 78 b. The prongs 78 a and 78 b are sized and configured to fit within the inner diameter of the applicable solder sleeve. More specifically, the prongs 78 a and 78 b are tapered along their lengths so that they easily enter the solder sleeve 12 as the solder sleeve is moved into position. Preferably the prongs 78 a and 78 b are made of a material having a low coefficient of friction (e.g., metal) so that the cable 10 may easily slide along the interior surface of the prong. Also the prongs 78 a and 78 b are thin enough that the prongs do not adversely impact the cable's ability to fit through the solder sleeve 12. The prongs 78 a and 78 b preferably have smooth interior surfaces devoid of rough patches or sharp edges that might damage the shield 4 and/or cable 10. The prongs 78 a and 78 b close off a large portion of the internal surface of the solder sleeve 12, and provide a smooth surface for the cable 10 to slide along as it is fed through the open-top funnel 170 and the solder sleeve 12. The prongs 78 a and 78 b eliminate the need to create, and then later remove, a sacrificial jacket slug.

When the trimmed shield cable 10 is inserted through the solder sleeve 12, snagging or otherwise catching of the shield strands or wire ends against the inner surface of the solder sleeve (which could damage the cable) is prevented by the intervening prongs 78 a and 78 b. The size and length of the funnel extensions are designed/determined based on the size of the solder sleeve 12 to be installed. The prongs 78 a and 78 b should be long enough to extend through at least a portion if not most of the solder sleeve 12, and should taper down along the length of the prongs 78 a and 78 b to facilitate easy placement of the solder sleeve 12 over the prongs 78 a and 78 b.

FIG. 12 is a diagram showing a view of the components depicted in FIG. 11, with the addition of an end effector 108 for placing a solder sleeve 12 (not visible in FIG. 12, but see FIG. 13) onto a portion of a cable 10 having an exposed shield 4 as part of an automated solder sleeve installation operation. FIG. 12 depicts one state during the solder sleeve installation process wherein the solder sleeve 12 has already been placed around the funnel extension 172 b by the end effector 108 and the cable 10 has already been fed through the open-top funnel 170 b and solder sleeve 12.

More specifically, the solder sleeve installation process in accordance with one embodiment includes the following steps which are performed before the state of the apparatus depicted in FIG. 12 is attained, The end effector 108 picks up a solder sleeve 12 from a vibration table (or other sleeve supply mechanism), places it over the end of the funnel extension 172 b, and then in one embodiment remains stationary while the cable 10 is being fed through the solder sleeve 12 by the cable positioning mechanism 19. As seen in FIG. 12, the end effector 108 is equipped with a plastic cover plate 178 which closes off the open-top funnel 170 b to prevent the cable 10 from escaping the open-top funnel 170 b as it is fed through the solder sleeve 12. Next, in one embodiment, the end effector 108 remains holding the sleeve 12 with the wire inserted through it, and awaits the soldering operation to be performed on the sleeve. In another embodiment, the end effector 108 releases the solder sleeve 12 and moves out of the way prior to the solder sleeve melt process, which situation is shown in FIG. 13.

FIG. 13 is a diagram showing a view of the components depicted in FIG. 11 at an instant in time after a solder sleeve 12 has been placed on a funnel extension 172 b and after a cable 10 has been passed through the open-top funnel 170 b and the solder sleeve 12 as part of an automated solder sleeve installation operation. As seen in FIG. 13, the solder sleeve 12 is seated on the funnel extension 172 b. The funnel extension 172 b closes off a large portion of the internal surface of the solder sleeve 12, and provides a smooth surface for the cable 10 to slide along as it is fed through the open-top funnel 170 b and the solder sleeve 12.

The system controller (not shown in FIG. 13, but see system controller 100 in FIG. 20) may either calculates how far the cable positioning mechanism 19 (see FIG. 4B) should drive the cable 10 into the module based on cable strip length information or uses a known pre-set value. The cable shield 4 is stopped at a repeatable position for processing. Thereafter the end effector 108 (see FIG. 10B) moves the solder sleeve 12 to the repeatable position seen in FIG. 14 for processing. These repeatable positions are such that the solder sleeve 12 is centered over the exposed area of the trimmed shield 4 of the cable 10. In one embodiment, the end effector 108 then releases the solder sleeve 12 and moves out of the way (back to the origin position) prior to the start of the solder sleeve melt process. In another embodiment, the end effector 108 remains holding the sleeve 12 during the heating process. FIG. 14 shows one embodiment of an apparatus for melting a solder sleeve 12 onto a portion of a cable 10 having exposed shielding using hot air as part of an automated solder sleeve installation operation. The system controller 100 sends commands to a robotic apparatus that places the components of the heating tool 174 in the positions seen in FIG. 14. In this example, the heating tool 174 includes two hot air guns 174 a and 174 b placed on opposite sides of the solder sleeve 12 and a curved-tip nozzle 174 c attached to the outlet of the hot air gun 174 a. The curved-tip nozzle 174 c projects from the hot air gun 174 a and overhangs the solder sleeve 12. In addition, the hot air gun 174 b may have a flat-tip nozzle attached that is roughly the length of the solder sleeve. The hot air gun 174 b moves laterally from the right of the solder sleeve 12 into position. The hot air gun 174 a rotates down over the solder sleeve 12. The hot air guns 174 a and 174 b may be moved into heating position by activation of respective linear actuators (not shown). Other embodiments may use a single hot air gun, or more than two.

During the heating stage, the two hot air guns 174 a and 174 b apply heat to the solder sleeve 12. The curved-tip nozzle 174 c “reflects” the generated hot air and causes it to flow around the solder sleeve 12. The heating tool 174 generates sufficient heat in the heating zone that the solder ring 9 of the solder sleeve 12 melts onto the cable 10. Using two hot air guns improves the even application of heat to all sides of the solder sleeve 12, as well as enables an increase in the speed of the overall melting process. At no point should the hot air guns make physical contact with the solder sleeve 12 or cable 10 due to the possibility of charring or damaging the jacket 2 of the cable 10.

In accordance with alternative embodiments, other types of heating devices, such as infrared heaters, may be employed in the solder sleeve melting process. An infrared heater or heat lamp is a body with a higher temperature which transfers energy to a body with a lower temperature through electromagnetic radiation. Depending on the temperature of the emitting body, the wavelength of the peak of the infrared radiation ranges from 780 nm to 1 mm. No contact or medium between the two bodies is needed for the energy transfer.

FIG. 15 shows an infrared heating tool 94 in position to melt a solder sleeve 12 onto a portion of a cable 10 having exposed shielding as part of an automated solder sleeve installation operation. The infrared heating tool 94 includes a pair of quartz-encapsulated heating elements 120 a and 120 b which are plugged into respective heat sinks 121 a and 121 b. The quartz-encapsulated heating elements 120 a and 120 b, when closed, are configured to encircle a workpiece. Such heating elements are capable of providing instant radiant heat at temperatures up to 1500° F.

The heating process may be integrated with a method for performing an active monitoring method such as dimensional analysis to monitor solder sleeves during melting, or temperature monitoring to avoid over or spotty heating of the solder sleeve. In the case of dimensional analysis, laser measurement devices can be used and configured to record diameter data at specific points on the fused cable and solder sleeve in order to determine when the solder sleeve has been fully melted.

Once the solder sleeve 12 has been fully melted on the cable 10, the cable 10 may be popped up and out of the open-top funnel 170 b (e.g., by a pneumatic lever that lifts the cable 10 upward or manually) and then retracted back toward the pallet 64 by the cable positioning mechanism 19 (e.g., drive wheel 16 and idler wheel 18 shown in FIG. 4B) or manually.

FIG. 16 is a flowchart identifying steps of a method 200 for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment. First, the system controller 100 sends information to the computer 162 controlling operation of the solder sleeve pick, place and melt module (step 202). The information includes which type of solder sleeve to pick and the orientation of the pigtail if one is to be attached to the sleeve. An example of a pigtail could be an insulated ground wire, or a ground braid strap, or any other wire that needs to be attached to the cable 10. The solder sleeve type is used as a factor to determine which funnel of a set of funnels should be used to pass a cable through that solder shield.

In accordance with one proposed implementation, solder sleeves and dead end sleeves are separated by part number onto different vibration tables (not shown in the drawings). Vibration tables could be replaced with tape-and-reels or cartridges. The system controller 100 tells the robotic arm or gantry with the attached end effector 108 where to move based on the solder sleeve part number that is to be installed on a cable 10. If the solder sleeve 12 is on a tape-and-reel or cartridge (not shown in the drawings), the solder sleeve 12 will be pushed out of the cavity (via pneumatic actuator, electric actuator, etc.) so that the end effector 108 can grip it.

Next the gantry/robot arm positions an end effector over the location of solder sleeves of the correct type (step 204). A pick-and-place vision system is used to assist the positioning of the end effector to pick up a solder sleeve in the correct orientation (step 206). When the end effector is properly positioned and oriented, the end effector is actuated to grip a solder sleeve (step 208). A verification step is performed to ensure the solder sleeve has been gripped and that the ground wire of the gripped solder sleeve is correctly oriented. A vision system can be used for such purposes.

The gantry/robot arm then moves the end effector so that the gripped solder sleeve is transported toward a vicinity of the corresponding funnel and then placed on the prongs of the funnel extensions (step 210). While the solder sleeve is seated on the prongs, the cable positioning mechanism at the solder sleeve installation module pushes the cable through the funnel and the solder sleeve (step 212). In certain embodiments, the cable is pushed through only a certain pre-specified length that has been calculated or is pre-programmed according to the application, wire type and shield trim characteristics.

The gantry/robot arm then moves the end effector to a repeatable position for processing (step 214) while holding the sleeve 12. This position is such that the solder sleeve is centered over the exposed shield on the cable. In accordance with one embodiment, the exposed shield of the cable and the solder sleeve may be moved concurrently and at the same speed while the solder sleeve is already centered over the exposed shield. In accordance with other embodiments, the cable is fed through the funnel until the exposed shield of the cable arrives at the repeatable position and thereafter the end effector moves the solder sleeve off of the prongs to the repeatable position. In accordance with one proposed implementation, the respective repeatable positions of the solder sleeve and the exposed shield are such that the solder sleeve surrounds the entire exposed shield. The end effector is then actuated open to release the solder sleeve and then the gantry/robot arm is moved out of the way and possibly back to an origin position (step 216).

The heating tool is then moved into position within a heating zone of the solder sleeve and activated (step 218). The heating tool generates heat in the heating zone sufficient to melt the solder sleeve onto the cable. During the melting operation, the state of the solder sleeve is monitored using active dimensional analysis (step 220). For example, a laser scan micrometer may be used to measure the decreasing outer diameter of the solder sleeve. Once the solder sleeve is melted to the desired level, the heating process is stopped. This can be achieved by turning heating tool off and pulling it away from the cable (step 222). For example, when the laser measurement indicates that the outer diameter of the solder sleeve has reached a target value indicative of a state of fully melted or melted to a desired level, the heating process is stopped. This can be achieved by turning the heating tool, such as hot-air guns, off automatically. Then the cable is lifted at least partially out of the open-top funnel and then retracted out of the pick, place and melt module (step 224). In accordance with an alternative embodiment having split (not open-top) funnels, two funnel halves are opened to provide sufficient space for the sleeve-cable assembly 1 to be retracted.

FIG. 17 is a block diagram identifying some components of an automated system for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment. The computer 162 is programmed to send control signals to various electrically controlled valves 80 which may be opened to supply compressed air to pneumatic cylinders 84, 86 and 88 as previously described. The pneumatic cylinders 84, 86 and 88 may be used to move various components of the cable processing equipment 24, such as funnel halves 180 a, 180 b and hot air guns 174 a, 174 b. In alternative embodiments, the pneumatic cylinders may be replaced by electric motors.

Still referring to FIG. 17, the computer 162 communicates with a robot controller 98 via a suitable wired or wireless connection using a suitable communication protocol (e.g., Ethernet or Bluetooth). The robot controller 98 is a computer configured to control the operation of various robot motors 104 (via motor controllers 102) that move the gantry/robot arm 106 to achieve the previously described path for the end effector 108. The robot controller 98 is also configured to control the gripping action of the end effector 108.

The computer 162 also controls the temperature in the heating zone. More specifically, the computer 162 outputs heater power control signals that control the power supplied to the infrared heating tool 94. The heater power control signals are sent by the computer 162 to a signal conditioner 90, which in turn outputs conditioned heater power control signals to a heater power controller 92. The heater power controller 92 is configured to convert conditioned heater power control signals to an output voltage which is used to power the infrared heating tool 94. In accordance with one embodiment, the outer diameter of the solder sleeve 12 may be monitored during melting using a laser scan micrometer 96. In response to measurement data from laser scan micrometer 96 indicating that the outer diameter of the shrinking solder sleeve has reached a target value, the computer 162 turns the infrared heating tool 94 off.

The system depicted in FIG. 1 may be operated under the control of a system controller 150 (shown in FIG. 18). FIG. 18 is a flowchart identifying steps of a method 300 for controlling a system having a plurality of workstations for performing a sequence of operations for installing a solder sleeve 12 on an end of a cable 10 in accordance with one embodiment. The system controller 150 receives work packages and information 304 from a database 302 and also receives cable information 308 from static look-up tables 306. The system controller 150 parses the data and uses the information to run the system. The cables to be processed may be intended for installation on an airplane or other vehicle or in other types of electrical systems. In the case of cables intended for installation on an airplane, the cables in a work package are organized by airplane effectivity, bundle number, wire type, and then group code.

An example of a work package is production data or information and may include the wire bundle that includes the identifying numbers of the cable to be processed by the system and the solder sleeve to be installed the overall cable length, to what equipment the cable will connect from and to, the cable type, the airplane effectivity, what type of airplane (program code), the wire bundle dash number, the wire gauge (this is the gauge of the wires in the cable), the bundle group code, and the termination code (designates what kind of contact or other termination is applied to the wires and shield of the cable).

Static look-up tables are used to configure the system parameters based on the parameters of a cable in the production file (work package). Examples of data stored in the static lookup tables include: the size of the dead end sleeve that fits the cable; the size and type of solder sleeve that fits the cable; an alternative size of solder sleeve that fits the cable if the primary solder sleeve size is out of stock or otherwise unavailable; the size of funnel that should be used to feed the cable into the solder sleeve pick, place and melt station; the wire colors that are present on the cable (to be sent to the vision inspection system after the shield is trimmed); the solder sleeve “fully installed” diameter, which is the value that is sent to the solder sleeve pick, place and melt station if active dimensional analysis is used to monitor the installation of a sleeve part; the strip length of the cable if a solder sleeve is to be installed (which is determined by both what equipment the cable is terminated to, as well as the termination type code); the strip length of the cable if a dead end sleeve is to be installed; and the orientation of the ground wire (pigtail) if a solder sleeve is installed.

The system controller 150 sends signals for controlling movements of the various components of the cable delivery system 60 or 61 (step 316). The system controller 150 also receives signals representing the states of the light gates from all modules (step 309). The system controller 150 also determines, derives or retrieves from a lookup table how far the cable positioning mechanism 19 should drive the cable 10 into each module based on cable strip length information. The cable strip length is used to calculate the length of the cable that needs to be driven into each module such that the cable is processed at the correct location. The system controller 150 sends control signals to the various motor controllers (or computer in command of the motor controller) to cause the motors to move based on signals received from the various light gates and the cable strip length (step 318).

Still referring to FIG. 18, cables are sent one at a time to the de-reeler module 32 to be cut and loaded onto the system. The system controller 150 sends cable type and length information to the de-reeler module 32 (step 320). The de-reeler module 32 de-reels a continuous length of cable of the specified type and then cuts the cable to the specified length. For each length of cable 10, the laser marker 34 laser marks the outer jacket 2 of the cable 10 with pertinent information (bundle number, wire number, gauge).

In addition, the system controller 150 uses cable insulation information to select the appropriate laser setting and send it to the laser scoring module 40 (step 322). The system controller 150 also uses the cable type information to determine the correct type of solder sleeve or dead end sleeve and then sending commands to the solder sleeve installation modules 52 and 54 specifying which open-top funnel should be used (based on cable diameter) and where the solder sleeve 12 should be positioned after its removal from the prong (step 328). The same signals specifying which funnel should be used are sent to the shield trimming module 44 (step 324). In addition, the system controller sends cable type information to the shield trim inspection module 46 (step 326).

The system controller 150 is also configured to monitor the system for errors. For example, the system controller 150 receives signals from the shield sensor in the jacket slug pulling module 42 (step 310). If the signal is not present, the system controller 150 issues an error alarm. Also, the system controller 150 receives image data from cameras at the shield trim inspection module 46, which image data is processed using a pass/fail algorithm (step 312). In addition, the system controller 150 receives signals from the ground wire detection module 58 (step 314). If the signal is not present, the system controller 150 generates an error message.

The active dimensional analysis technique disclosed herein may be employed in an automated cable processing line (as disclosed above) or as part of a hands-free benchtop apparatus that melts and monitors solder sleeves for installation onto shielded cables. The benchtop apparatus comprises a heat source, a set of cable supports, a sensor system (e.g., a laser measurement system), and a control system (e.g., a computer) configured to generate an alert signal indicating that the solder sleeve melting process should be terminated in response to receipt of sensor data indicating that the solder sleeve is fully melted. The sensor system actively monitors the progress of the solder sleeve melt, ensuring that the solder sleeve is fully melted and damage-free. The heater may be de-activated and/or removed manually or automatically in response to generation of the alert signal.

FIG. 19 is a diagram representing a view of an infrared heater 94 (of the type depicted in FIG. 15 and previously described) in position to melt a solder sleeve 12 onto a portion of a cable 10 being supported by a pair of cable supports 122 a and 122 b. The cable supports 122 a and 122 b are affixed to a base plate 120. The cable 10 is immovably supported by the cable supports 122 a and 122 b during the solder sleeve melting process. When the infrared heater 94 is activated, the infrared heating elements 120 a and 120 b generate sufficient heat to melt the solder ring 9 of the solder sleeve 12 onto the cable 10.

In one embodiment, the cable supports 122 a and 122 b maintain the position of the cable 10 and solder sleeve 12 during processing. Many commercially available off-the-shelf options are available. For example, cable supports 122 a and 122 b may be wire clips commercially available from Panduit Corp., Tinley Park, Ill. The material of the cable supports 122 a and 122 b should be rigid enough to maintain hold on the cable 10 and the solder sleeve grounding wire (not shown in FIG. 19, but see grounding wire 14 in FIGS. 8A and 9A). If an open-clip design is used (similar to what is shown in FIG. 19), the prongs of the wire clip must have enough flexibility to allow the operator to push the cable 10 (including exposed wires 6 and 8) and the solder sleeve grounding wire 14 into the wire clip. Furthermore, the cable supports 122 a and 122 b should be made of a material that is heat resistant (e.g., polycarbonate or silicone) if the cable supports 122 a and 122 b are located close to the heating elements 120 a and 120 b, as depicted in FIG. 19. If located a sufficient distance away from heating elements 120 a and 120 b, the material of the cable supports 122 a and 122 b does not necessarily have to be heat-resistant (e.g., a thermoplastic material).

In all cases, a monitoring method is used to monitor the melting state of the sleeve and cause the melting process to stop when needed. Examples of such methods include but are not constrained to temperature monitoring and dimensional analysis. Temperature monitoring can be used to ensure the sleeve is not being over melted overall or in certain spots, or to ensure the sleeve is not overheating in certain spots.

Active dimensional analysis is another method using scanning laser beams that may be employed with the set-up depicted in FIG. 19, as previously described with reference to FIG. 15, which showed two laser beams L1 and L2 at one instant in time. During the solder sleeve melting process, photoelectric sensors (e.g., laser measurement devices) can be activated to scan a beam of light vertically across the melting solder sleeve, acquiring sensor data that indicates the instantaneous height (or outer diameter) of the solder sleeve 12 at one or more locations along the length of the solder sleeve 12. Each photoelectric sensor is positioned so that the vertically scanning light beam is not blocked by one of the heating elements 120 a and 120 b.

The diameter of the cable 10 is actively measured and the shrinking diameter of the solder sleeve 12 is actively monitored in real-time during the melt process. This can be achieved by using a photoelectric sensor system. Various sensors configured to measure diameters are commercially available off the shelf, including photoelectric sensors that use laser scanning, shadow projection, laser shadow projection and CCD line sensors. The photoelectric sensor should be oriented such that the transmitted light beams impinge upon the solder sleeve 12 in a vertical plane that intersects the solder sleeve 12 without interference from the heating elements.

FIG. 20 is a diagram representing a view of a photoelectric sensor 124 in position to measure a dimension of a solder sleeve 12 on a cable 10 being held by a single wire clip 122 mounted on a base 120. The heater is not shown to avoid clutter in the drawing. In the example depicted in FIG. 20, the photoelectric sensor 124 is a laser scan micrometer having a laser transmission module 126 and a laser detection module 128. In a laser scanner of this type, a scanning laser beam is emitted from the laser transmission module 126, which scanning laser beam scans in a scanning plane and is then received by the laser detection module 128. In accordance with one embodiment, the laser detection module 128 includes a linear array of light-detecting elements (e.g., a column of pixels in a charge coupled device). The edges in the acquired image data where transitions in the interruption of light occur (e.g., a transition from the scanning laser beam light not being interrupted to being interrupted or vice versa) are detected by the laser detection module 128). This type of laser sensor may be used for sleeve outer diameter measurement.

FIG. 21 is a diagram identifying components of a commercially available photoelectric sensor 124 that is suitable for use in the active dimensional analysis system proposed herein. The photoelectric sensor 124 depicted in FIG. 21 includes a polygonal mirror 148 mounted on the output shaft of a motor 144. Rotation of the polygonal mirror 148 is controlled by a motor controller 146 which receives clock pulses from a clock 188 and converts those clock pulses into motor drive pulses. The photoelectric sensor 124 depicted in FIG. 21 further includes a laser driver 138 that drives a laser 140 to generate a laser beam that is directed at a mirror 142 (or other reflective surface). The mirror 142 is oriented such that the projected laser beam is reflected onto the polygonal mirror 148 rotating at high speed in exact synchronism with clock pulses from the clock 188. As the angle of each reflective facet of the polygonal mirror 148 changes during rotation, a vertically scanning laser beam is reflected by each facet onto a collimating lens 150. The reflected beam sweeps across the input surface of the collimating lens 150 but changes direction to be horizontal after the lens' exit surface as the beam scans downward. This horizontal beam enters the measuring space and, with no workpiece present, reaches a photodetector 154 via a condensing lens 152.

The photodetector 154 converts the impinging light into electrical signals which are amplified by an amplifier 156. The amplified electrical signals are then passed through an edge detection circuit 182 which detects edges corresponding to the transitions between the solder sleeve 12 obstructing and not obstructing light. The edge detection circuit 182 outputs a characteristic signal when an edge is detected, which characteristic signal is received by a gate which flip-flops between open and closed states in response to receipt of successive characteristic signals indicating first and second edges of the solder sleeve 12. When the scanning laser light transitions from being not obstructed by the solder sleeve 12 to being obstructed, the gate 184 opens and passes the clock pulses from clock 188 to a counter 186, which starts to count. Later when the scanning laser light transitions from being obstructed by the solder sleeve 12 to being no longer obstructed, the gate 184 closes and blocks passage of the clock pulses to the counter 186, thereby stopping the counter. A central processing unit 190 (hereinafter “CPU 190”) is configured to detect when the count has stopped, send the count to a computer (e.g., computer 164 identified in FIG. 17) and then reset the counter to zero. This process is repeated for each scanning laser beam.

As depicted in FIG. 21, laser beams which are obstructed by the solder sleeve 12 do not impinge upon the photodetector 154. When a solder sleeve 12 is placed into the measuring space, the scanning laser beam will be interrupted for a time during its sweep and the duration of this interruption, as indicated by a count of clock pulses occurring while the receiver signal is absent, is proportional to the workpiece dimension in the downward direction.

The computer 164 is configured to compare each incoming instantaneous count to a target count corresponding to a target dimension of the solder sleeve 12. When the count indicating the instantaneous measurement of a dimension of the solder sleeve 12 equals the target count, in one embodiment, the computer 164 issues an alert signal to notify the operator that the solder sleeve is fully melted. This alert signal may be transduced into an aural or visual form, such as an aural alarm or a flashing display. In another embodiment, the computer causes the melting process to stop and optionally causes the heating tools to move away from the heating zone.

FIG. 22 is a flowchart identifying steps of a method 250 for using active dimensional analysis during a manual solder sleeve installation procedure in accordance with one embodiment. First, the operator selects the correct solder sleeve type for the particular shielded cable type being processed (step 252). Then the operator places the solder sleeve on an end of the shielded cable having exposed shield with the grounding wire oriented either out front or out back (step 254). Next the operator verifies that the solder sleeve is axially positioned to surround the exposed shield (step 256). Then a determination is made whether the solder ring (see solder ring 9 in FIG. 7A) is centered on the exposed shield or not (step 258). If a determination is made in step 258 that the solder ring is centered on the exposed shield, then the cable and exposed wires (including the grounding wire) are placed in a pair of clamps with the solder sleeve between the clamps (step 260). If a determination is made in step 258 that the solder ring is not centered on the exposed shield, then the solder sleeve is repositioned and aligned (step 262). Step 260 is performed after step 262.

The clamps holding the cable may be affixed to a plate. In that case, the operator slides the plate into the melt chamber (step 264). Then the heating mechanism (e.g., hot air guns or infrared heating elements) is moved into the active position surrounding the solder sleeve (step 266). Then the heating mechanism and the laser measurement system are activated (steps 268 and 270). During heating, the solder ring melts and the sleeve shrinks (step 272). The laser measuring system actively monitors the dimension of the solder sleeve (step 274) and a computer determines when the melt process is complete (274). If the computer determines that the melting process is incomplete, the heat continues to be applied, causing the sleeve to shrink more (step 272). If the computer determines that the melting process is complete, then the melt mechanism is deactivated (turned off) and moved to an inactive position (step 276). The plate to which the cooling cable is clamped is then moved out of the melt chamber (step 278). The sleeve-cable assembly with fully melted solder sleeve is then removed from the clamps (step 280).

While methods and apparatus for installing a sleeve on a cable have been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the teachings herein. In addition, many modifications may be made to adapt the teachings herein to a particular situation without departing from the scope thereof. Therefore it is intended that the claims not be limited to the particular embodiments disclosed herein.

The embodiments disclosed above use one or more computer systems. As used in the claims, the term “computer system” comprises a single processing or computing device or multiple processing or computing devices that communicate via wireline or wireless connections. Such processing or computing devices typically include one or more of the following: a processor, a computer, a controller, a central processing unit, a microcontroller, a reduced instruction set computer processor, an application-specific integrated circuit, a programmable logic circuit, a field-programmable gated array, a digital signal processor, and/or any other circuit or processing device capable of executing the functions described herein. For example, the control computer 162 and robot controller 98 identified in FIG. 17 form a “computer system”. The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the term “computer system”.

Certain aspects of the methods described herein may be encoded as executable instructions embodied in a non-transitory tangible computer-readable storage medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processing or computing system, cause the system device to perform at least a portion of the methods described herein.

The process claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order (any alphabetical ordering in the claims is used solely for the purpose of referencing previously recited steps) or in the order in which they are recited unless the claim language explicitly specifies or states conditions indicating a particular order in which some or all of those steps are performed. Nor should the process claims be construed to exclude any portions of two or more steps being performed concurrently or alternatingly unless the claim language explicitly states a condition that precludes such an interpretation. 

1-8. (canceled)
 9. A method for melting an object on a cable, the method comprising: (a) positioning an object on a cable in a heating zone; (b) using a heat source to produce enough heat in the heating zone to melt material of the object; (c) measuring a dimension of the object during melting; and (d) changing a state of the heat source so that the heat source ceases producing heat in the heating zone in response to the measured dimension becoming equal to a target dimension.
 10. The method as recited in claim 9, further comprising issuing an alert signal when the measured dimension becomes equal to the target dimension, wherein step (d) is performed by a human operator after the alert signal has been issued.
 11. The method as recited in claim 9, wherein step (d) is performed by a computer system.
 12. The method as recited in claim 9, wherein the object is a sleeve and step (c) comprises measuring an outer diameter of the sleeve.
 13. The method as recited in claim 9, wherein step (d) comprises moving the heat source away from the object.
 14. The method as recited in claim 9, wherein step (d) comprises de-activating the heat source.
 15. The method as recited in claim 9, wherein step (c) comprises: transmitting light that scans in a scanning plane intersecting the heating zone; issuing a first edge detection signal indicating that interruption of the transmitted light has started; starting a count of clock pulses in response to receipt of the first edge detection signal; issuing a second edge detection signal indicating that interruption of the transmitted light has stopped; and stopping the count of clock pulses in response to receipt of the second edge detection signal.
 16. The method as recited in claim 15, further comprising comparing the stopped count to a target count corresponding to a target dimension of the object, wherein step (d) comprises controlling the heater to cease producing heat in the heating zone in response to the stopped count becoming equal to the target count.
 17. The method as recited in claim 9, wherein step (a) comprises: placing the object around the cable; and supporting the cable using a cable support that is positioned and configured to support a portion of the cable so that the object placed around the cable is in the heating zone.
 18. The method as recited in claim 9, wherein step (a) comprises: placing a portion of the cable between a pair of wheels that form a nip; robotically placing the object on an extension of a funnel having an entry side that faces the nip; and driving rotation of the wheels in a cable pushing direction to cause an end of the cable to move through the funnel and object and into the heating zone. 19-20. (canceled)
 21. A method for melting a sleeve on a cable, the method comprising: placing a sleeve on a cable; supporting the cable between a set of cable supports positioned on opposite sides of a heating zone, the cable being supported in a position so that the sleeve is in the heating zone; using a heat source to produce heat in the heating zone; acquiring sensor data that is a measure of a dimension of the sleeve during melting; computing a measured value of the dimension of the sleeve using the sensor data; and issuing an alert signal if the measured value becomes equal to a target value corresponding to a fully melted sleeve.
 22. The method as recited in claim 21, wherein supporting the cable between a set of cable supports comprises push fitting the cable into a set of wire clips.
 23. The method as recited in claim 21, further comprising changing a state of the heat source so that the heat source ceases producing heat in the heating zone in response to issuing the alert signal.
 24. The method as recited in claim 21, wherein the dimension of the sleeve that is measured is an outer diameter of the sleeve.
 25. The method as recited in claim 23, wherein changing the state of the heat source comprises moving the heat source away from the sleeve.
 26. The method as recited in claim 23, wherein changing the state of the heat source comprises de-activating the heat source.
 27. The method as recited in claim 23, wherein acquiring sensor data comprises: transmitting light that scans in a scanning plane intersecting the heating zone; issuing a first edge detection signal indicating that interruption of the transmitted light has started; starting a count of clock pulses in response to receipt of the first edge detection signal; issuing a second edge detection signal indicating that interruption of the transmitted light has stopped; and stopping the count of clock pulses in response to receipt of the second edge detection signal.
 28. The method as recited in claim 27, further comprising comparing the stopped count to a target count corresponding to a target dimension of the sleeve, wherein changing the state of the heat source comprises controlling the heater to cease producing heat in the heating zone in response to the stopped count becoming equal to the target count.
 29. The method as recited in claim 21, wherein placing the sleeve on the cable comprises: placing a portion of the cable between a pair of wheels that form a nip; robotically placing the sleeve on an extension of a funnel having an entry side that faces the nip; and driving rotation of the wheels in a cable pushing direction to cause an end of the cable to move through the funnel and sleeve and into the heating zone.
 30. A method for melting a sleeve on a cable, the method comprising: placing a portion of a cable between a pair of wheels that form a nip; robotically placing a sleeve on an extension of a funnel having an entry side that faces the nip; driving rotation of the wheels in a cable pushing direction to cause an end of the cable to move through the funnel and sleeve and into a heating zone; moving the sleeve away from the extension and onto the end of the cable in the heating zone; using a heat source to produce heat in the heating zone sufficient to at least partially melt the sleeve; acquiring sensor data that is a measure of a dimension of the sleeve during melting; computing a measured value of the dimension of the sleeve using the sensor data; and changing a state of the heat source to cease producing heat in response to the measured value becoming equal to a target value corresponding to a fully melted sleeve. 